6. Sequencing
The sequencing of installations is also a key part of retrofitting different enclosures and façades. It is important to develop a phasing and logistics plan and manage that plan as the project scope and design progress.
If a building is occupied, renovations must be completed in phases. As with most renovations and retrofits, existing materials and systems will be completely or selectively removed. If there are limits to how much scope can be removed and installed before moving to another phase, this will increase the cost of the project and bidders should be made aware of this information. That is why all parties involved in planning the project should take the time to coordinate early.
7. Material Lead Times
As with any project, developing an accurate schedule is crucial; this begins with knowing the lead time of materials. With the inherent phasing and sequencing of renovations and retrofits, managing materials to fit within project needs is even more important. Take the time to under- stand what the lead times are for products used on the project. Are there any products or systems coming from overseas and what is the lead time associated? If a part breaks, how long will it take to receive a replacement?
Asking these questions early in the process ensures the team responsible for executing the work has the right information from which to plan.
One of the ways to manage current supply-chain challenges is early procurement. Bringing the right entities on board early can assist with early procurement. For example, if the lead time for roof insulation is 10 months and a traditional design-bid-build delivery does not allow that amount of time, it would be worth considering bringing a roofing contractor onboard in the design development phase and ordering the insulation as early as possible.
8. Preservation
Finally, knowing the history of the community where the project is taking place is essential to a retrofit project. Stakeholders must understand historic preservation requirements. When it comes to preserving the history of a building, renovations will always require more consideration than new builds.
Many times, projects can be required to receive approvals from historic review boards. Building-code requirements and historic-preservation requirements may not align with each other. In addition, there can be different requirements for preserving versus replacing, and it’s important
to understand how those requirements will impact the project. Consulting early and often with historic review boards and building-code officials can save a lot of work and anxiety.
Retrofitting a building enclosure can be challenging. Preparation, communication and planning can lead to a high-quality project compatible with the original structure. Taking these steps during the early stages of the project will create fewer problems and lead to success.
The 8 Steps Are Executed on City Foundry STL
IWRNorth America, a specialty contractor providing turnkey building enclosure and metal design services, has followed these eight best practices on a number of building enclosure retrofit projects. One such project was City Foundry STL, a unique dining hall experience; the complex also features office space, retail options, three major entertainment venues and an esports gaming center.
The 180,000-square-foot, 15-acre complex opened in St. Louis in 1929 as Century Electric Foundry, where various electric motors and automotive parts were produced for 40 years. After standing vacant for 10 years with signs of neglect, it was added to the National Register of Historic Places. The facility was purchased in 2015 and converted into its new use, opening in 2020. The redevelopment project preserved the character and building infrastructure of the historic building.
For example, as part of its interior design, the remains of two concrete kilns were transformed into a unique seating option within the dining hall. Guests can look to the sky and be amazed by hoppers, catwalks, rolling cranes, 2-ton hoists and foundry salvage that have been transformed into art.
For IWR North America, one of the project’s challenges, as with many retrofit projects, is understanding what existing structural supports would be kept and determining if they were in adequate condition for the project. Much of the steel and other substructure supports for the new façade and claddings were partially or completely covered and could not be physically inspected until selective demolition was complete and the substructure was exposed. Fortunately, it was discovered early in the project that much of the substructure was inadequate and needed to be replaced or reinforced before installing the new claddings and façade. Having discovered this, the general contractor adjusted the phasing and sequencing to allow the selective demolition and physical verification of any concealed substructure to be inspected and mitigated as early as possible to prevent delays.
Today, City Foundry STL attracts people to the area not only for what’s inside the building but also for its pedestrian-only streetway, which can be used for art fairs, concerts, farmers markets, street performers and events. In addition, the project preserves the significance of this industrial
building in St. Louis’ history.
PHOTOS: courtesy IWR North America